Special end cutting edge attached cutter for carbon fiber reinforced polymer/plastic with designable micro-tooth configuration

Abstract

A special end cutting edge attached cutter for carbon fiber reinforced polymer/plastic with designable micro-tooth configuration, having an end cutting edge, a peripheral cutting edge with variation inverse helical groove, a peripheral cutting edge with constant inverse helical groove and a shank. Two parallel V-shaped chip pockets are designed on the end cutting edge of the cutter in two cutting edge directions which are symmetrical around a cutter axis as a center. The structure may enhance chip removal performance during high-speed milling of impenetrable slots and impenetrable windows, reduce wear of the end cutting edge, conduct configuration design for micro-teeth of the peripheral cutting edge, reduce the cutting thickness of the micro-tooth cutting edges, and effectively solve the problem of damage of the micro-tooth edges. A section of peripheral cutting edge with variation left-hand inverse helical flute angle is designed near the end cutting edge.

1 . A special end cutting edge attached cutter for carbon fiber reinforced polymer/plastic with designable micro-tooth configuration, wherein the special end cutting edge attached cutter with designable micro-tooth configuration for CFRP comprises an end cutting edge, a peripheral cutting edge with variation inverse helical groove, a peripheral cutting edge with constant inverse helical groove and a shank;
 wherein the end cutting edge is designed with a rake face of end cutting edge, a flank face of end cutting edge, and a secondary flank face of end cutting edge, and also has a chip pocket of end cutting edge; parallel V-shaped chip pockets are designed on the end cutting edge in two cutting edge directions which are symmetrical around a cutter axis as a center, and the V-shaped chip pocket presents such a structural shape that a bottom is narrow and a top is wide; to ensure that the V-shaped chip pocket has good chip removal performance and is closely connected with the chip pocket of end cutting edge, the sizes of a design structure of the V-shaped chip pocket are determined: the bottom width is L 1 , the top width of V-shaped chip pocket is L 2 , the depth of the V-shaped chip pocket is L 3  and tilt angles of two side surfaces of the V-shaped chip pocket satisfy δ 1 =δ 2 ;   the peripheral cutting edge with variation inverse helical groove is of an asymmetric- and spiral-stagger structure, and m right-hand flutes and n left-hand flutes are staggered to form a plurality of equidimensional micro-teeth; to reduce the vibration of the end cutting edge and a transition part of peripheral cutting edge during slot milling, a section of peripheral cutting edge with variation left-hand inverse helical flute angle is designed near the end cutting edge; the peripheral cutting edge with variation left-hand inverse helical flute angle points to the end cutting edge direction and the change relationship of the helical angle of the left-hand flutes is γ 1 <γ 2 <γ 3 ;   a three-dimensional stereographic cutter is sectioned along an axial direction and then is unfolded; the peripheral cutting edge with constant inverse helical groove that represents the configuration mode is selected to form a two-dimensional schematic diagram of micro-tooth configuration of the cutter by using a tangential direction and an axial direction to form a coordinate system; the right-hand flutes and the left-hand flutes are staggered to form micro-teeth; the micro-teeth comprise a lower cutting edge and an upper cutting edge; in the design process of the cutter, tool geometric parameters are known, i.e., length A of the micro-tooth, width B of the right-hand flute, helical angle θ of the right-hand flute, number of milling blade Z 1  and milling cutter diameter D; the configuration mode of the micro-teeth is mainly determined by the following variables: tangential length d of the left-hand flute, tangential length c between adjacent micro-teeth, helical angle β of the left-hand flute, tangential length f of micro-tooth, and number Z 2  of the left-hand flute; specific steps of the design method are as follows:   step 1: calculating the tangential length c between adjacent micro-teeth through the milling cutter diameter D and the number Z 1  of milling blade;   
       
         
           
             
               
                 
                   
                     c 
                     = 
                     
                       
                         n 
                         × 
                         D 
                       
                       
                         Z 
                         1 
                       
                     
                   
                 
                 
                   
                     ( 
                     1 
                     ) 
                   
                 
               
             
           
         
         step 2: selecting the tangential length d of the left-hand flute as an independent variable parameter; establishing a triangle using the width B of the right-hand flute and the tangential length d of the left-hand flute as sides; and calculating the helical angle β of the left-hand flute through the geometrical relationship of the triangle: 
       
       
         
           
             
               
                 
                   
                     
                       
                         sin 
                          
                         
                             
                         
                          
                         
                           ( 
                           
                             θ 
                             + 
                             β 
                           
                           ) 
                         
                       
                       d 
                     
                     = 
                     
                       
                         cos 
                          
                         
                             
                         
                          
                         β 
                       
                       B 
                     
                   
                 
                 
                   
                     ( 
                     2 
                     ) 
                   
                 
               
             
           
         
         similarly, establishing a triangle by using the length A of the micro-tooth and the tangential length f of the micro-tooth as side lengths; and calculating the tangential length f of the micro-tooth and the number Z 2  of left-hand flute through the geometrical relationship of the triangle; 
       
       
         
           
             
               
                 
                   
                     
                       
                         sin 
                          
                         
                             
                         
                          
                         
                           ( 
                           
                             θ 
                             + 
                             β 
                           
                           ) 
                         
                       
                       f 
                     
                     = 
                     
                       
                         cos 
                          
                         
                             
                         
                          
                         β 
                       
                       A 
                     
                   
                 
                 
                   
                     ( 
                     3 
                     ) 
                   
                 
               
               
                 
                   
                     f 
                     = 
                     
                       
                         ( 
                         
                           π 
                           × 
                           
                             D 
                             ÷ 
                             
                               Z 
                               2 
                             
                           
                         
                         ) 
                       
                       - 
                       d 
                     
                   
                 
                 
                   
                     ( 
                     4 
                     ) 
                   
                 
               
             
           
         
         step 3: judging whether the relationship d<c<f is satisfied; if so, covering the lower cutting edge and the upper cutting edge of each micro-tooth by the cutting edge of a previous micro-tooth so that two edges of each micro-tooth are overlapped; if not, returning to step 2 to reselect the tangential length d of inverse flute.